Windows, Doors, and Roof Penetrations

Techniques, Risks, and Standards

James D Katsaros, PhD DuPont Building Innovations / DuPont Flashing Systems

Chairman, FMA Installation Committee

Outline

 The Role and Importance of Flashing

 Guiding Principles for Installation

 What does the Code say about Flashing?

 Installation Standard Practices

 Regional Considerations / Wall System Variations

  FMA Installation Committee

Flashing is a Key Part of the Weatherization System

“Configuration of materials that are arranged to direct water to the exterior.”

Fine Homebuilding April/May 1998

Illustration from the EEBA Water Management Guide, 2002

The Role and Importance of Flashing

The Five Most Common Mistakes Leading to Water Intrusion

  Improperly flashed doors and windows   No exterior drainage plane   Reversed shingling of flashing or housewrap and

other moisture barriers   Improper grading to keep water away from

foundation walls   No kick-out flashing to keep rainwater from

running behind the cladding and get trapped in the wall

Adapted from “Keeping Mold at Bay”, Rural Builder, March 2003

Improper Flashing & Installation is a Key Source of Building Damage/Litigation

“…most leakage problems are related to improper or insufficient flashing details or the absence of flashing…”

Durability by Design guideline published by the Partnership of Advancing Technology in Housing (PATH)

Flashing Application Principles

Guiding Principles for Installation of Windows and Doors

  Continuity of Window-Wall Interface

  Correct Shingling / Lapping of Materials

  Provide a Drainage Path for Leaks

  Test Window-Wall Installation as Complete System

  Installation Conditions (real life) that promotes adhesion (self-adhered flashings)

  Material Durability for Anticipated Exposure

  Training / Hands-On Support

  Risk Tolerance

Recognition of Common Installation Errors: Reversed shingling and detached flashing gaps between the window, flashing & weather barrier

Lack of Continuity at the sill…..

Key Flashing & Installation Codes & Standards KEY WINDOW / DOOR INSTALLATION STANDARDS:

•   ASTM E2112 – generic guidance for standard flanged windows, very comprehensive & hard to follow

•   FMA/AAMA 100 – ‘extreme exposure’ for wood frame construction, mandates sill pan flashing, “coastal region” wall

•   FMA/AAMA 200 – surface barrier CMU systems, the “Florida” wall

•   AAMA 2400 – open stud construction, the ‘southwest’ wall

•   FMA 300/400 series – door installations under development

FLASHING CODES •   IRC R703.8 – describes flashing principles (must be applied with correct shingling,

drainage to WRB or exterior, install guidelines, etc)

•   IRC R613.1 – designates responsibility to window manufacturer to provide written flashing and installation instructions for each window

FLASHING MATERIAL STANDARDS: •   AAMA 711-07 – self-adhered flashing products

•   AAMA 712-XX – mechanically attached flashing (under development)

Currently Regional Standards…May Effect National Codes More In Future.

What does the Code Say About Flashing? 2009 IRC Code -- Flashing

1. R 703.8 Flashing. Approved corrosion-resistant flashing shall be applied shingle-fashion in such a manner to prevent entry of water into the wall cavity or penetration of water to the building structural framing components. Self-adhered membranes used as flashing shall comply with AAMA 711. The flashing shall extend to the surface of the exterior wall finish. Approved corrosion-resistant flashings shall be installed at all of the following locations:

•   AAMA 711-07 referenced in IRC to define Acceptable Self-Adhered Flashing Products.

- Does not address non-self adhered (metal flashing, nail-on, etc.)

AAMA 711-07 Material Property Standard for Self-Adhered Flashings Implemented!

Physical Property Requirements: Tensile strength, peel adhesion to common substrates, cold temperature pliability

Performance Requirements: Nail sealability, adhesion after temperature cycling, minimum widths

Durability: Properties after UV aging, thermal exposure, water immersion

Self-Adhered flashing must be at least 4” wide and installed 2” beyond critical interface.

Installation Standards

ASTM E2112 Installation Practice

First Broadly Recognized Standard for Installation of Windows, Doors and Skylights

Details 4 Methods based on Flashing / WRB Sequencing

Not in format that can be used on job site

Really only covers integral flanged windows on wood frame walls

Can’t cover the world with one Standard

Flashing Method Selection Chart (Based on windows with mounting flanges being installed in membrane/drainage-type wall

systems)

A B

Flashing will be applied AFTER the

window or OVER the face of the mounting

flange

Flashing will be applied BEFORE the window or BEHIND

the face of the mounting flange

II WRB is applied AFTER the window installation

Use Method “A” Use Method “B”

I WRB is to be applied FIRST or BEFORE the window installation

Use Method “A1” Use Method “B1”

From ASTM E2112, “Standard Practice for Installation of Exterior Windows, Doors and Skylights”, Table 9

Original ASTM E2112-01 – Original Standard:

From ASTM E2112, “Standard Practice for Installation of Exterior Windows, Doors and Skylights”, Figures 11 & 15

Original ASTM E2112-01 – Barrier System (basis for Installation Masters Training)

In Out

Barrier Installation Method Risks

Advantages: Ease & Cost of Installation

Concerns: Unforgiving to leaks in Window or Window-wall interface

New ASTM E2112-07 Adds Drainage System

Drawings taken from ASTM E2112, “Standard Practice for

Installation of Exterior Windows, Doors and Skylights”, Figures 11 & 15

!!!

In Out

No Caulk on Bottom Flange

New ASTM E2112-07 Is Launched:

Recommends sill pans!

Recognizes self-adhered flashing widths other than 9”!!

Modified “I-Cut” Method

Inside Wall

Modified “I-Cut” Method

DuP

ont

C

ontr

acto

r Tap

e DuP

ont

C

ontr

acto

r Tap

e DuPont Contractor Tape

DuPont Contractor Tape

3” 6”

Modified “I-Cut” Method

DuPont Contractor Tape

DuPont Contractor Tape

DuPont Contractor Tape

DuPont

Contractor Tape

DuPont

Contractor Tape

DuPont

Contractor Tape

Inside Wall

Back Dam and Air Seal

Challenges for Installation of Windows & Doors… Will your window be installed the same in climate zone 1 as it is in 7? Will your installation guides be applicable to all regional practices and wall systems?

These highly variable fenestrations are installed a wide variety of climates, exposures and regional practices…

….that Desperately Need Regionally Specific Installation Details!

Challenges for Installation of Windows & Doors…

Open Stud Construction

Surface Barrier CMU Walls

Recessed Windows

Windows Before WRB

Windows After WRB

Brickmold Windows

Aluminum Windows

Low E glazing / Insulated cavity

Vinyl Windows Wood Windows

Concrete Slab Floors

High Wind / Rain Exposure

Hurricane Exposure

Extreme Temp Swings

Foam Sheathing

Extreme Storms

FMA / AAMA

AAMA 2400

FMA Installation Committee •  Original Mission (2005): to develop enhanced

installation methods for adoption into Florida Building Code

•  AAMA & WDMA Joined Effort – Full Industry Representation

•  Objective has expanded to include training / education to SE regional specific installation considerations

•  Developing several “window / wall system” regionally specific installation guidelines - Eventual adoption into ASTM E2112

•  Unique installation considerations: 1) extreme / coastal exposure and 2) surface barrier CMU construction

FMA Installation Standards Document Fenestration Wall System Status (more details to follow)

FMA / AAMA 100-07

Flanged or Mounting Fins (Wood, Al, or Vinyl)

Wood Frame Initial publication in 2007.

Republish in 2011 based on revisions from other docs.

FMA / AAMA 200-09

Frontal Flanged (Aluminum and Vinyl)

Surface Barrier CMU

Published in 2009

FMA / WDMA 250-10

Non-frontal flanged (Wood)

Surface Barrier CMU

Published in 2010

FMA / AAMA / WDMA 300

Exterior Doors with mounting fins, brick mold and box frame.

Wood Frame wall / Concrete slab and wood floors

Completed first draft and testing at ATI Tamp – September, 2010

FMA / AAMA / WDMA 400

Exterior Doors Surface Barrier CMU Walls / Concrete slab floors

Will begin in early 2011

FMA / AAMA 100 Wood Frame Wall System

FMA_AAMA 100-07 Installation Guideline Published for Wood Framed Wall System (residential) under Extreme Exposure Conditions

Details generic A1 (WRB before) flashing method based on both 4” self-adhered flashing and 9” mechanically attached flashing. Other sequences acceptable, but not detailed.

Mandates drainage method / use of sill pan flashing (extreme exposure on water sensitive frame)

Tested to 12 psf, (~70 mph winds) using the ASTM E331 or ASTM E547 water test, to simulate extreme exposure conditions. This pressure was selected based on the AAMA / WDMA / CSA 101/IS2/A440-05 criteria.

Unique Installation Considerations

Surface Barrier CMU Wall System

Current Wall Water Management Strategy:

1)   Use the storage capacity of masonry wall to contain moisture

2)   Rely on HVAC to handle inward driven moisture from hot/humid climate

3)   Fill cracks / joints with paint / sealant (need to do this at least twice)

When and where will cracks occur?

Most vulnerable around the window/wall interface!

FMA / AAMA 200 – FMA/WDMA 250 Coastal S/E Wall System:

Direct applied Stucco onto CMU Wall

Figure taken from Lstiburek Design

FMA/AAMA 200 – FMA/WDMA 250 Require sealant on Rough Opening return and precast sill. Seal on face (either external or internal) is optional ‘recommended practice’ / not mandatory.

Benefit: Protects rough opening without impacting exterior surface interface with Stucco.

This is the design in FMA/AAMA 2000-09 & FMA/WDMA 250-10

AAMA Liquid Applied Flashing Material Performance Standard AAMA task group formed to define material property requirements – task group meets at AAMA National meetings & interim conference calls

Application as specified for use in FMA/AAMA 200 & FMA/WDMA 250 standard practices for sealing CMU surface

This is NOT just a block sealant – needs to bridge gaps, seal through fasteners, have abrasion resistance & durability, and be compatible to surface applied stucco

It is essential that an installation method is tested at the window / wall interface as an installed system.

Window and wall are usually tested separately.

+ =

Installation Testing •   All FMA Installation Standards include testing of

representative mockup installations Testing has been conducted at ATI (York & Tampa) and the Univeristy of Florida Hurricane Research Center - Hurricane Simulator led by Dr Forrest Masters

•   Test water intrusion path(s) under extreme wind/water exposure (hurricane force wind driven rain)

•   Test various fenestration types and installation methodologies - includes wood frame and CMU walls

FMA/AAMA/WDMA 300 Series

300 – Detailas for Flanged, BrickMold, and Non-flanged / Box Frame Doors

Wood Frame Construction

Concrete (recessed or flat) or Wood Sill

Representative specimens tested to high level exposure at ATI, Tampa

Guiding Principles for Installation of Windows and Doors

  Continuity of Window-Wall Interface

  Correct Shingling / Lapping of Materials

  Provide a Drainage Path for Leaks

  Test Window-Wall Installation as Complete System

  Installation Conditions (real life) that promotes adhesion (self-adhered flashings)

  Material Durability for Anticipated Exposure

  Training / Hands-On Support

  Risk Tolerance

Key Risk Factors for Installation Considerations

Exposure •   Rainfall

•   Temperature (hot, cold, cycles)

•   Humidity / Drying Potential

•   Window / Wall Design (overhangs, recessed, bump out?)

Moisture Tolerance •   Wall Assembly (wood frame or masonry)

•   Reliable Drainage Path to Exterior (new construction vs replacement)

•   Window System (wood or vinyl)

Workmanship •   Labor Skill Level

•   Complexity of Detail

•   HANDS ON TRAINING!

Risk Tolerance

It is essential that an installation method is tested at the window / wall interface as an installed system.

Window and wall are usually tested separately.

+ =

It is also essential that an installation is tested at the Renewable Energy / Roof interface as an installed system.

Photovoltaic Modules and Roofs are usually tested separately.

+ =

Considerations for Solar / Roof Interface

Worker Safety Protection – Roofers / Electricians / Installers

Material Durability – Roofing Products

Flammability Impact

Performance Through Expected Loads & Exposures

Energy Production at High Temperatures

Water Shedding Ability – Prevention of Roof Leaks

Impact on Roof Service Life / Warranty

Design / Aesthetics / Shading Concerns

PV / Roof Standards and Guidelines

Designation: WK21327 (For Task Group Use Only – Not an Approved Standard) ENGLISH

ASTM E44 Task Group NRCA

Thank You For the Opportunity!

Round Top Windows

Reverse Shingling At Window Head

What’s Wrong????

Wrapped In At The Window Head

What’s Wrong????

Improper Penetrations

What’s Wrong????

Wrapped In At The Window Head

Flashing Pictures

Heading Flashing Stops Short of Jamb Flashing

Flashing Pictures

Fastener in Corner/Exposed Wood

Flashing Pictures

Flashing Not Adhering

REF: Weston T. A., et al.,“Performance Testing of Window Installation and Flashing Details” 2002 Symposium on Improving Building Systems in Hot & Humid Climates, May

Installed Window –Wall Testing Protocol

AAMA 2400 For Open Frame Construction

Originally developed for California wall system – published in 2002, now being revised.

Describes an exterior barrier system, with a warning in the Forward about associated risks - “recommended for installations at low risk of water intrusion”

DuPont Nail-on Flashing Installation Guide will be drainage system, but can reference AAMA 2400 for barrier installations